Method for creating a textured press plate

ABSTRACT

Disclosed is a method for creating a textured press plate. Initially, a mask may be applied to a surface of a press plate. This mask typically corresponds to a desired physical surface structure. Thereafter, the masked surface of the press plate is processed to obtain the desired physical surface structure. Thereafter, various techniques may be used to create differing degrees of gloss in differing portions of the surface of the press plate. For example, matting may be used to decrease the degree of gloss of a portion of the surface, and polishing may be used to increase the degree of gloss of a portion of the surface.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of patent application Ser. No.15/293,175, filed Oct. 13, 2016 and titled “METHOD FOR CREATING ATEXTURED PRESS PLATE,” which further claims the benefit of U.S.Provisional Application No. 62/240,869, filed Oct. 13, 2015, titled“METHOD FOR CREATING A TEXTURED PRESS PLATE,” each of which is herebyincorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention embraces a method for creating a textured pressplate. Initially, the surface of the press plate is processed to obtainthe desired physical surface structure. Thereafter, various techniquesmay be used to create differing degrees of gloss in differing portionsof the surface of the press plate.

BACKGROUND

Decorative laminates have been used as surfacing material for manyyears, in both commercial and residential applications. Decorativelaminates can provide an aesthetically pleasing surface that is moreeconomical and/or has improved physical characteristics compared tosimilar looking alternatives. For example, decorative laminates can beused to create flooring that has the appearance of real hardwoodflooring but is less expensive and more durable than real hardwoodflooring.

In addition to flooring, decorative laminates are often used infurniture, countertops, cabinets, wall paneling, partitions, fixtures,and the like. As described above, decorative laminates can be made toresemble real wood. Decorative laminates can also be made to resemblesuch other materials and surfaces as stone, ceramic, marble, concrete,leather, fabric, brick, tile, and the like. In other applications,instead of being made to resemble a particular traditional material orsurface, a decorative laminate may be made to provide more fancifulsurfaces.

More recently, decorative laminates have been improved to include athree-dimensional “textured” surface. In this way, decorative laminatescan be made to not only look like some other material or surface, butcan also be made to feel like the other material or surface. In fact,decorative laminates can be made to so closely resemble the look andfeel of other materials that one cannot easily determine whether thesurface includes the real materials or is a faux representation of thereal materials. For example, a textured decorative laminate made to looklike real wood paneling may include a plurality of depressions and/orprotrusions on its surface to create a texture that simulates the grainsand knots of real wood boards. In another example, the textureddecorative laminate may be made to look like a plurality of ceramictiles separated by grout lines. In such an embodiment, the surface ofthe laminate may be made so that the images of the grout lines aredepressed relative to the images of the ceramic tiles. In still otherapplications, textured decorative laminates may be made with morefanciful virtual artwork and may have embossing and textures that workin conjunction with the virtual artwork to create a more interesting andaesthetically pleasing surface.

In order to create a textured laminate, a press plate having depressionsand/or protrusions arranged in a three-dimensional design may be pressedinto a substrate. When the press plate is physically pressed into thesubstrate, the substrate is imprinted with the three-dimensional designpresent in the surface of the press plate.

To create a textured press plate, a rigid substrate may be preciselyground until a press plate substrate is substantially flat. Thereafter,a selected texture design (e.g., mask) may be printed onto the substrateto guide a subsequent etching process. Once the design is properlyprinted, various surface portions of the substrate may be etched basedon the printed design to create a three-dimensional surface thereon. Theresult of this etching transforms the substrate into a textured (e.g.,three-dimensional) press plate that can be used to produce textureddecorative laminates.

In some instances, textured laminates that have multiple degrees ofgloss may be desirable. In this regard, having multiple degrees of glossmay increase the variety of shadings and color reflects of a texturedlaminate, thus making the textured laminate appear more realistic.Therefore, a need exists for an improved method of creating a pressplate having multiple degrees of gloss.

SUMMARY

In one aspect, the present invention embraces a method for creating atextured press plate.

In one embodiment, a method for creating a textured press plateincludes: applying a mask to a working surface of a press plate,processing the working surface of the press plate to obtain a structurein the working surface of the press plate, polishing the working surfaceof the press plate, cleaning the working surface of the press plate,applying a first metallic coating to the entire working surface of thepress plate; applying a first protective layer over portions of theworking surface of the press plate; adjusting a level of gloss for aportion of the working surface of the press plate not covered by thefirst protective layer; removing the first protective layer; applying asecond metallic coating to the entire working surface of the pressplate; applying a second protective layer over portions of the workingsurface of the press plate; adjusting a level of gloss for a portion ofthe working surface of the press plate not covered by the secondprotective layer; removing the second protective layer; and applying athird metallic coating to the entire working surface of the press plate.

In some embodiments of the method, the first metallic coating, thesecond metallic coating, or the third metallic coating comprises achromium plating.

In some embodiments of the method, adjusting the level of gloss for theportion of the working surface of the press plate not covered by thefirst protective layer further comprises: polishing the working surfaceof the press plate not covered by the first protective layer; mattingthe working surface of the press plate not covered by the firstprotective layer; or applying a new metallic coating to the workingsurface of the press plate not covered by the first protective layer.

In some embodiments of the method, adjusting the level of gloss for theportion of the working surface of the press plate not covered by thesecond protective layer further comprises: polishing the working surfaceof the press plate not covered by the second protective layer; mattingthe working surface of the press plate not covered by the secondprotective layer; or applying a new metallic coating to the workingsurface of the press plate not covered by the second protective layer.

The method may also comprise, in response to adjusting the level ofgloss for the portion of the working surface of the press plate notcovered by the first protective layer, applying a new protective layerover portions of the working surface of the press plate; and adjustingthe level of gloss for the portion of the working surface of the pressplate not covered by the new protective layer.

Finally, in some embodiments, the method further comprises, afterprocessing the working surface of the press plate to obtain thestructure in the working surface of the press plate, applying a new maskto the working surface of a press plate; and processing the workingsurface of the press plate to obtain an additional structure in theworking surface of the press plate at portions of the working surface ofthe press plate that are not covered by the new mask.

In another embodiment, a textured press plate product is prepared,manufactured, or otherwise created by a process comprising the steps of:applying a mask to a working surface of a press plate; processing theworking surface of the press plate to obtain a structure in the workingsurface of the press plate; polishing the working surface of the pressplate; cleaning the working surface of the press plate; applying a firstmetallic coating to the entire working surface of the press plate;applying a first protective layer over portions of the working surfaceof the press plate; adjusting a level of gloss for a portion of theworking surface of the press plate not covered by the first protectivelayer; removing the first protective layer; applying a second metalliccoating to the entire working surface of the press plate; applying asecond protective layer over portions of the working surface of thepress plate; adjusting a level of gloss for a portion of the workingsurface of the press plate not covered by the second protective layer;removing the second protective layer; and applying a third metalliccoating to the entire working surface of the press plate.

In some embodiments of the process for preparing the textured pressplate product, the first metallic coating, the second metallic coating,or the third metallic coating comprises a chromium plating.

In some embodiments of the process for preparing the textured pressplate product, adjusting the level of gloss for the portion of theworking surface of the press plate not covered by the first protectivelayer further comprises: polishing the working surface of the pressplate not covered by the first protective layer; matting the workingsurface of the press plate not covered by the first protective layer; orapplying a new metallic coating to the working surface of the pressplate not covered by the first protective layer.

In some embodiments of the process for preparing the textured pressplate product, adjusting the level of gloss for the portion of theworking surface of the press plate not covered by the second protectivelayer further comprises: polishing the working surface of the pressplate not covered by the second protective layer; matting the workingsurface of the press plate not covered by the second protective layer;or applying a new metallic coating to the working surface of the pressplate not covered by the second protective layer.

Furthermore, in some embodiments, the process by which the texturedpress plate product is prepared further comprises: in response toadjusting the level of gloss for the portion of the working surface ofthe press plate not covered by the first protective layer, applying anew protective layer over portions of the working surface of the pressplate; and adjusting the level of gloss for the portion of the workingsurface of the press plate not covered by the new protective layer.

Additionally, in some embodiments, the process by which the texturedpress plate product is prepared further comprises: in response toadjusting the level of gloss for the portion of the working surface ofthe press plate not covered by the second protective layer, applying anew protective layer over portions of the working surface of the pressplate; and adjusting the level of gloss for the portion of the workingsurface of the press plate not covered by the new protective layer.

Finally, some embodiments of the process for preparing the texturedpress plate product comprise: after processing the working surface ofthe press plate to obtain the structure in the working surface of thepress plate, applying a new mask to the working surface of a pressplate; and processing the working surface of the press plate to obtainan additional structure in the working surface of the press plate atportions of the working surface of the press plate that are not coveredby the new mask.

Another embodiment comprises a textured press plate, wherein a workingsurface of the textured press plate comprises: a first chromium platinglayer formed over the entire base press plate layer, wherein a surfaceof the first chromium plating layer comprises varied gloss levels; asecond chromium plating layer formed over the entire first chromiumplating layer, wherein a surface of the second chromium plating layercomprises varied gloss levels; and a third chromium plating layer formedover the entire second chromium plating layer.

In one embodiment, a method for creating a textured press plateincludes: applying a mask to a surface of a press plate; processing thesurface of the press plate to obtain a surface structure in the surfaceof the press plate; polishing the surface of the press plate; cleaningthe surface of the press plate; matting the surface of the press plateto obtain a first degree of gloss on the surface of the press plate;applying a first protective layer over portions of the surface of thepress plate; polishing the surface of the press plate to obtain a seconddegree of gloss on the surface of the press plate; applying a metalliccoating to the surface of the press plate; applying a second protectivelayer over portions of the surface of the press plate; and matting thesurface of the press plate to obtain a third degree of gloss on thesurface of the press plate.

In another embodiment, a method for creating a textured press plateincludes: applying a mask to a surface of a press plate; processing thesurface of the press plate to obtain a surface structure in the surfaceof the press plate; polishing the surface of the press plate; cleaningthe surface of the press plate; matting the surface of the press plateto obtain a first degree of gloss on the surface of the press plate;applying a first protective layer over portions of the surface of thepress plate; polishing the surface of the press plate to obtain a seconddegree of gloss on the surface of the press plate; applying a secondprotective layer over portions of the surface of the press plate;matting the surface of the press plate to obtain a third degree of glosson the surface of the press plate; and applying a metallic coating tothe surface of the press plate.

In another embodiment, a method for creating a textured press plateincludes: applying a mask to a surface of a press plate; processing thesurface of the press plate to obtain a surface structure in the surfaceof the press plate; polishing the surface of the press plate; cleaningthe surface of the press plate; matting the surface of the press plateto obtain a first degree of gloss on the surface of the press plate;applying a first protective layer over portions of the surface of thepress plate; polishing the surface of the press plate to obtain a seconddegree of gloss on the surface of the press plate; applying a metalliccoating to the surface of the press plate; applying a second protectivelayer over portions of the surface of the press plate; polishing thesurface of the press plate to obtain a third degree of gloss on thesurface of the press plate; applying a third protective layer overportions of the surface of the press plate; and matting the surface ofthe press plate to obtain a fourth degree of gloss on the surface of thepress plate.

In another embodiment, a method for creating a textured press plateincludes: applying a mask to a surface of a press plate; processing thesurface of the press plate to obtain a surface structure in the surfaceof the press plate; polishing the surface of the press plate; cleaningthe surface of the press plate; matting the surface of the press plateto obtain a first degree of gloss on the surface of the press plate;applying a first protective layer over portions of the surface of thepress plate; polishing the surface of the press plate to obtain a seconddegree of gloss on the surface of the press plate; applying a metalliccoating to the surface of the press plate; applying a second protectivelayer over portions of the surface of the press plate; matting thesurface of the press plate to obtain a third degree of gloss on thesurface of the press plate; applying a third protective layer overportions of the surface of the press plate; and polishing the surface ofthe press plate to obtain a fourth degree of gloss on the surface of thepress plate.

In another embodiment, a method for creating a textured press plateincludes: applying a mask to a surface of a press plate; processing thesurface of the press plate to obtain a surface structure in the surfaceof the press plate; polishing the surface of the press plate; cleaningthe surface of the press plate; applying a metallic coating to thesurface of the press plate to obtain a first degree of gloss on thesurface of the press plate; applying a first protective layer overportions of the surface of the press plate; matting the surface of thepress plate to obtain a second degree of gloss on the surface of thepress plate; applying a second protective layer over portions of thesurface of the press plate; and polishing the surface of the press plateto obtain a third degree of gloss on the surface of the press plate.

In another embodiment, a method for creating a textured press plateincludes: applying a mask to a surface of a press plate; processing thesurface of the press plate to obtain a surface structure in the surfaceof the press plate; polishing the surface of the press plate; cleaningthe surface of the press plate; applying a first protective layer overportions of the surface of the press plate; polishing the surface of thepress plate to obtain a first degree of gloss on the surface of thepress plate; applying a second protective layer over portions of thesurface of the press plate; matting the surface of the press plate toobtain a second degree of gloss on the surface of the press plate; andapplying a metallic coating to the surface of the press plate.

The features, functions, and advantages that have been discussed may beachieved independently in various embodiments of the present inventionor may be combined with yet other embodiments, further details of whichcan be seen with reference to the following description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described embodiments of the invention in general terms,reference will now be made the accompanying drawings, wherein:

FIG. 1 depicts a general process flow 100 for creating a textured pressplate in accordance with one embodiment of the present invention.

FIG. 2 depicts a general process flow 200 for creating a textured pressplate in accordance with another embodiment of the present invention.

FIG. 3 depicts a general process flow 300 for creating a textured pressplate in accordance with another embodiment of the present invention.

FIG. 4 depicts a general process flow 400 for creating a textured pressplate in accordance with another embodiment of the present invention.

FIG. 5 depicts a general process flow 500 for creating a textured pressplate in accordance with another embodiment of the present invention.

FIG. 6 depicts a general process flow 600 for creating a textured pressplate in accordance with another embodiment of the present invention.

FIG. 7 depicts a general process flow 700 for creating a textured pressplate in accordance with another embodiment of the present invention.

FIG. 8 depicts a general process flow 800 for creating a textured pressplate in accordance with another embodiment of the present invention.

FIG. 9 depicts a textured press plate comprising varied levels of gloss,in accordance with another embodiment of the present invention.

FIG. 10 depicts a press plate as it undergoes a series of steps toachieve a textured surface with varied levels of gloss, in accordancewith embodiments of the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

Embodiments of the present invention will now be described more fullyhereinafter with reference to the accompanying drawings, in which some,but not all, embodiments of the invention are shown. Indeed, theinvention may be embodied in many different forms and should not beconstrued as limited to the embodiments set forth herein; rather, theseembodiments are provided so that this disclosure will satisfy applicablelegal requirements. Where possible, any terms expressed in the singularform herein are meant to also include the plural form and vice versa,unless explicitly stated otherwise. Also, as used herein, the term “a”and/or “an” shall mean “one or more,” even though the phrase “one ormore” is also used herein. Furthermore, when it is said herein thatsomething is “based on” something else, it may be based on one or moreother things as well. In other words, unless expressly indicatedotherwise, as used herein “based on” means “based at least in part on”or “based at least partially on.” Like numbers refer to like elementsthroughout.

In one aspect, the present invention embraces a method for creating atextured press plate. Typically, the press plate is initially processedto create a desired structure in the surface of the press plate.Thereafter, various techniques may be used to create differing degreesof gloss in differing portions of the surface of the press plate. Forexample, matting may be used to decrease the degree of gloss of aportion of the surface, and polishing may be used to increase the degreeof gloss of a portion of the surface. Additionally or alternatively, ametallic coating (e.g., chromium plating) may be applied to the surfaceof the press plate, where the metallic coating provides an increased ordecreased level of gloss for the surface of the press plate. In someembodiments, the metallic coating is applied to the entire surface ofthe press plate, or at least in the entire surface of the press platethat will be used to stamp out panels, flooring, or the like. In otherembodiments, a protective layer is applied to the surface of the pressplate before the metallic coating is applied, thereby coating onlyportions of the press plate surface that are not covered by theprotective layer. The application of a metallic coating, includingchromium plating, to the surface of the press plate provides a change tothe level(s) of gloss on the surface, added protection to the structuredsurface, added protection to any previous gloss-adjusting steps, andcreates a stable point from which additional gloss-adjusting steps canbe applied. The textured press plate may then be used to create acorresponding textured laminate having multiple degrees of gloss.

FIG. 1 depicts a general process flow 100 for creating a textured pressplate in accordance with one embodiment of the present invention.Initially, at block 105, a mask is applied to a surface of a pressplate. Typically, the press plate is rigid and metallic. For example,the press plate may be made from stainless steel (e.g., 410- or630-grade hardened stainless steel). That said, it is within the scopeof the present invention for the press plate to be formed of othermaterials.

Typically, the mask corresponds to a desired physical surface structure(e.g., a wood-like structure) for the surface of the press plate. Inparticular, the mask typically defines which areas of the press platewill be etched and which areas will not be etched in a subsequentprocessing step that creates the desired surface structure. As such, thematerial used to create the mask is typically resistant to one or morechemical solutions that may be used for etching. The mask may beprinting on the surface of the press plate (e.g., via a digital printingtechnique). In this regard, U.S. Pat. No. 8,778,202, which is herebyincorporated by reference in its entirety, depicts a method of applyinga chemically resistant ink to the surface of a press plate.

Next, at block 110, the masked surface of the press plate is processedto obtain the desired surface structure. Typically, the press plate isprocessed via chemical etching (e.g., using a ferric chloride solution).Typically, areas of the press plate surface covered by the mask are notetched, and areas of the press plate surface not covered by the mask areetched.

At blocks 115 and 120 the surface of the press plate is typicallypolished and cleaned. In this regard, the surface of the press plate maybe polished via mechanical polishing or electropolishing. Cleaning andpolishing of the surface of the press plate may include degreasing thesurface and removing the mask. Cleaning and polishing of the surface ofthe press plate may also include activating the surface of the pressplate. Activating the surface of the press plate may improve theadhesion of subsequent layers/coatings to the press plate.

At block 125, the surface of the press plate is matted to obtain a firstdegree of gloss on the surface of the press plate. Matting of the pressplate may be performed via matte etching or sandblasting. In someembodiments, prior to matting the surface of the press plate, aprotective layer is applied over portions of the surface so that onlyportions of the press plate not covered by such protective layer willhave the first degree of gloss.

At blocks 130 and 135, a protective layer is applied over portions ofthe surface of the press plate, and the surface is polished (e.g., viamechanical polishing or electropolishing) to achieve a second degree ofgloss. This protective layer is typically formed from a material that isresistant to polishing. Following the polishing at block 135, the areasof the surface covered by the protective layer will typically retain thefirst degree of gloss, and the areas of the surface not covered by theprotective layer will typically have the second degree of gloss.

At block 140, a metallic coating is typically applied to the surface ofthe press plate. Typically, the metallic coating functions to protectthe press plate and may be quite hard, which aids the use of the pressplate in pressing operations. Chromium plating is typically used, butthe use of other metallic coatings is within the scope of the presentinvention. In some embodiments, the metallic coating functions toprovide a further degree of gloss to the press plate. In some instances,a protective layer is applied over portions of the surface of the pressplate prior to applying the metallic coating so that the metalliccoating is only applied to areas not covered by such protective layer.

Optionally, at blocks 145 and 150, a protective layer is applied overportions of the surface of the press plate, and the surface is polished(e.g., via mechanical polishing or electropolishing) to achieve a thirddegree of gloss. This protective layer is typically formed from amaterial that is resistant to polishing. Following the polishing atblock 150, the areas of the surface covered by the protective layer willtypically retain (as applicable) either the first degree of gloss or thesecond degree of gloss, and the areas of the surface not covered by theprotective layer may have the third degree of gloss.

FIG. 2 depicts a general process flow 200 for creating a textured pressplate in accordance with another embodiment of the present invention.Initially, at block 205, a mask is applied to a surface of a pressplate. Next, at block 210, the masked surface of the press plate isprocessed (e.g., via chemical etching) to obtain a desired surfacestructure. At blocks 215 and 220 the surface of the press plate istypically polished and cleaned. In some embodiments, cleaning andpolishing the surface of the press plate may include activating thesurface of the press plate. At block 225, the surface of the press plateis matted (e.g., via matte etching or sandblasting) to obtain a firstdegree of gloss on the surface of the press plate. In some embodiments,prior to matting the surface of the press plate, a protective layer isapplied over portions of the surface so that only portions of the pressplate not covered by such protective layer will have the first degree ofgloss.

At blocks 230 and 235, a protective layer is applied over portions ofthe surface of the press plate, and the surface is polished (e.g., viamechanical polishing or electropolishing) to achieve a second degree ofgloss. Following the polishing at block 235, the areas of the surfacecovered by the protective layer will typically retain the first degreeof gloss, and the areas of the surface not covered by the protectivelayer will typically have the second degree of gloss.

At block 240, a metallic coating (e.g., chromium plating) is typicallyapplied to the surface of the press plate. In some embodiments, themetallic coating functions to provide a further degree of gloss to thepress plate. In some instances, a protective layer is applied overportions of the surface of the press plate prior to applying themetallic coating so that the metallic coating is only applied to areasnot covered by such protective layer.

At blocks 245 and 250, a protective layer is applied over portions ofthe surface of the press plate, and the surface is matted (e.g., viamatte etching or sandblasting) to achieve a third degree of gloss. Thisprotective layer is typically formed from a material that is resistantto matting. Following the matting at block 250, the areas of the surfacecovered by the protective layer will typically retain (as applicable)either the first degree of gloss or the second degree of gloss, and theareas of the surface not covered by the protective layer may have thethird degree of gloss.

Optionally, at block 255, a second metallic coating (e.g., chromiumplating) may be applied to the surface of the press plate. In someembodiments, the metallic coating functions to provide a further degreeof gloss to the press plate. In some instances, a protective layer isapplied over portions of the surface of the press plate prior toapplying the metallic coating so that the metallic coating is onlyapplied to areas not covered by such protective layer.

FIG. 3 depicts a general process flow 300 for creating a textured pressplate in accordance with another embodiment of the present invention.Initially, at block 305, a mask is applied to a surface of a pressplate. Next, at block 310, the masked surface of the press plate isprocessed (e.g., via chemical etching) to obtain a desired surfacestructure. At blocks 315 and 320 the surface of the press plate istypically polished and cleaned. In some embodiments, cleaning andpolishing the surface of the press plate may include activating thesurface of the press plate. At block 325, the surface of the press plateis matted (e.g., via matte etching or sandblasting) to obtain a firstdegree of gloss on the surface of the press plate. In some embodiments,prior to matting the surface of the press plate, a protective layer isapplied over portions of the surface so that only portions of the pressplate not covered by such protective layer will have the first degree ofgloss.

At blocks 330 and 335, a protective layer is applied over portions ofthe surface of the press plate, and the surface is polished (e.g., viamechanical polishing or electropolishing) to achieve a second degree ofgloss. Following the polishing at block 335, the areas of the surfacecovered by the protective layer will typically retain the first degreeof gloss, and the areas of the surface not covered by the protectivelayer will typically have the second degree of gloss.

At blocks 340 and 345, a protective layer is applied over portions ofthe surface of the press plate, and the surface is matted (e.g., viamatte etching or sandblasting) to achieve a third degree of gloss. Thisprotective layer is typically formed from a material that is resistantto matting. Following the matting at block 345, the areas of the surfacecovered by the protective layer will typically retain (as applicable)either the first degree of gloss or the second degree of gloss, and theareas of the surface not covered by the protective layer may have thethird degree of gloss. The steps described with respect to blocks 340and 345 may be repeated for portions of the surface of the press plateto achieve additional degrees of gloss (e.g., a fourth or fifth degreeof gloss).

Finally, at block 350, a metallic coating (e.g., chromium plating) istypically applied to the surface of the press plate. In someembodiments, the metallic coating functions to provide a further degreeof gloss to the press plate. In some instances, a protective layer isapplied over portions of the surface of the press plate prior toapplying the metallic coating so that the metallic coating is onlyapplied to areas not covered by such protective layer.

FIG. 4 depicts a general process flow 400 for creating a textured pressplate in accordance with another embodiment of the present invention.Initially, at block 405, a mask is applied to a surface of a pressplate. Next, at block 410, the masked surface of the press plate isprocessed (e.g., via chemical etching) to obtain a desired surfacestructure. At blocks 415 and 420 the surface of the press plate istypically polished and cleaned. In some embodiments, cleaning andpolishing the surface of the press plate may include activating thesurface of the press plate. At block 425, the surface of the press plateis matted (e.g., via matte etching or sandblasting) to obtain a firstdegree of gloss on the surface of the press plate. In some embodiments,prior to matting the surface of the press plate, a protective layer isapplied over portions of the surface so that only portions of the pressplate not covered by such protective layer will have the first degree ofgloss.

At blocks 430 and 435, a protective layer is applied over portions ofthe surface of the press plate, and the surface is polished (e.g., viamechanical polishing or electropolishing) to achieve a second degree ofgloss. Following the polishing at block 435, the areas of the surfacecovered by the protective layer will typically retain the first degreeof gloss, and the areas of the surface not covered by the protectivelayer will typically have the second degree of gloss.

At block 440, a metallic coating (e.g., chromium plating) is typicallyapplied to the surface of the press plate. In some embodiments, themetallic coating functions to provide a further degree of gloss to thepress plate. In some instances, a protective layer is applied overportions of the surface of the press plate prior to applying themetallic coating so that the metallic coating is only applied to areasnot covered by such protective layer.

At blocks 445 and 450, a protective layer is applied over portions ofthe surface of the press plate, and the surface is polished (e.g., viamechanical polishing or electropolishing) to achieve a third degree ofgloss. Following the polishing at block 450, the areas of the surfacecovered by the protective layer will typically retain (as applicable)either the first degree of gloss or the second degree of gloss, and theareas of the surface not covered by the protective layer may have thethird degree of gloss.

At blocks 455 and 460, a protective layer is applied over portions ofthe surface of the press plate, and the surface is matted (e.g., viamatte etching or sandblasting) to achieve a fourth degree of gloss. Thisprotective layer is typically formed from a material that is resistantto matting. Following the matting at block 460, the areas of the surfacecovered by the protective layer will typically retain (as applicable)either the first, second, or third degree of gloss, and the areas of thesurface not covered by the protective layer may have the fourth degreeof gloss. The steps described with respect to blocks 455 and 460 may berepeated for portions of the surface of the press plate to achieveadditional degrees of gloss (e.g., a fifth or sixth degree of gloss).

FIG. 5 depicts a general process flow 500 for creating a textured pressplate in accordance with another embodiment of the present invention.Initially, at block 505, a mask is applied to a surface of a pressplate. Next, at block 510, the masked surface of the press plate isprocessed (e.g., via chemical etching) to obtain a desired surfacestructure. At blocks 515 and 520 the surface of the press plate istypically polished and cleaned. In some embodiments, cleaning andpolishing the surface of the press plate may include activating thesurface of the press plate. At block 525, the surface of the press plateis matted (e.g., via matte etching or sandblasting) to obtain a firstdegree of gloss on the surface of the press plate. In some embodiments,prior to matting the surface of the press plate, a protective layer isapplied over portions of the surface so that only portions of the pressplate not covered by such protective layer will have the first degree ofgloss.

At blocks 530 and 535, a protective layer is applied over portions ofthe surface of the press plate, and the surface is polished (e.g., viamechanical polishing or electropolishing) to achieve a second degree ofgloss. Following the polishing at block 535, the areas of the surfacecovered by the protective layer will typically retain the first degreeof gloss, and the areas of the surface not covered by the protectivelayer will typically have the second degree of gloss.

At block 540, a metallic coating (e.g., chromium plating) is typicallyapplied to the surface of the press plate. In some embodiments, themetallic coating functions to provide a further degree of gloss to thepress plate. In some instances, a protective layer is applied overportions of the surface of the press plate prior to applying themetallic coating so that the metallic coating is only applied to areasnot covered by such protective layer.

At blocks 545 and 550, a protective layer is applied over portions ofthe surface of the press plate, and the surface is matted (e.g., viamatte etching or sandblasting) to achieve a third degree of gloss. Thisprotective layer is typically formed from a material that is resistantto matting. Following the matting at block 550, the areas of the surfacecovered by the protective layer will typically retain (as applicable)either the first degree of gloss or the second degree of gloss, and theareas of the surface not covered by the protective layer may have thethird degree of gloss. The steps described with respect to blocks 545and 550 may be repeated for portions of the surface of the press plateto achieve additional degrees of gloss (e.g., a fourth or fifth degreeof gloss).

At blocks 555 and 560, a protective layer is applied over portions ofthe surface of the press plate, and the surface is polished (e.g., viamechanical polishing or electropolishing) to achieve a final degree ofgloss (e.g., a fourth of fifth degree of gloss). Following the polishingat block 560, the areas of the surface covered by the protective layerwill typically retain a prior degree of gloss, and the areas of thesurface not covered by the protective layer may have the final degree ofgloss.

FIG. 6 depicts a general process flow 600 for creating a textured pressplate in accordance with another embodiment of the present invention.Initially, at block 605, a mask is applied to a surface of a pressplate. Next, at block 610, the masked surface of the press plate isprocessed (e.g., via chemical etching) to obtain a desired surfacestructure. At blocks 615 and 620 the surface of the press plate istypically polished and cleaned. In some embodiments, cleaning andpolishing the surface of the press plate may include activating thesurface of the press plate.

At block 625, a metallic coating (e.g., chromium plating) is typicallyapplied to the surface of the press plate to achieve a first degree ofgloss. In some instances, a protective layer is applied over portions ofthe surface of the press plate prior to applying the metallic coating sothat the metallic coating is only applied to areas not covered by suchprotective layer.

At blocks 630 and 635, a protective layer is applied over portions ofthe surface of the press plate, and the surface is matted (e.g., viamatte etching or sandblasting) to achieve a second degree of gloss. Thisprotective layer is typically formed from a material that is resistantto matting. Following the matting at block 635, the areas of the surfacecovered by the protective layer will typically retain the first degreeof gloss, and the areas of the surface not covered by the protectivelayer will typically have the second degree of gloss. The stepsdescribed with respect to blocks 630 and 635 may be repeated forportions of the surface of the press plate to achieve additional degreesof gloss (e.g., a third or fourth degree of gloss).

At blocks 640 and 645, a protective layer is applied over portions ofthe surface of the press plate, and the surface is polished (e.g., viamechanical polishing or electropolishing) to achieve a subsequent degreeof gloss (e.g., a third of fourth degree of gloss). Following thepolishing at block 645, the areas of the surface covered by theprotective layer will typically retain a prior degree of gloss, and theareas of the surface not covered by the protective layer may have thesubsequent degree of gloss. Finally, the steps described with respect toblocks 640 and 645 may be repeated for portions of the surface of thepress plate to achieve additional degrees of gloss (e.g., a fourth orfifth degree of gloss).

In some embodiments, the steps described with respect to blocks 640 and645 may be performed prior to the steps described with respect to blocks630 and 635 (i.e., so that one or more degrees of gloss are created viapolishing before one or more degrees of gloss are created via matting).

FIG. 7 depicts a general process flow 700 for creating a textured pressplate in accordance with another embodiment of the present invention.Initially, at block 705, a mask is applied to a surface of a pressplate. Next, at block 710, the masked surface of the press plate isprocessed (e.g., via chemical etching) to obtain a desired surfacestructure. At blocks 715 and 720 the surface of the press plate istypically polished and cleaned. In some embodiments, cleaning andpolishing the surface of the press plate may include activating thesurface of the press plate.

At blocks 725 and 730, a protective layer is typically applied overportions of the surface of the press plate, and the surface is polished(e.g., via mechanical polishing or electropolishing) to achieve a firstdegree of gloss. Following the polishing at block 730, the areas of thesurface not covered by the protective layer will typically have thefirst degree of gloss. That said, in some embodiments, a protectivelayer might not be applied over portions of the surface of the pressplate prior to polishing the surface. The steps described with respectto blocks 725 and 730 may be repeated for portions of the surface of thepress plate to achieve additional degrees of gloss (e.g., a second orthird degree of gloss).

At blocks 735 and 740, a protective layer is applied over portions ofthe surface of the press plate, and the surface is matted (e.g., viamatte etching or sandblasting) to achieve a further degree of gloss(e.g., a second or third degree of gloss). This protective layer istypically formed from a material that is resistant to matting. Followingthe matting at block 740, the areas of the surface covered by theprotective layer will typically retain a previous degree of gloss (e.g.,the first degree of gloss), and the areas of the surface not covered bythe protective layer may have the further degree of gloss. The stepsdescribed with respect to blocks 735 and 740 may be repeated forportions of the surface of the press plate to achieve additional degreesof gloss (e.g., a third or fourth degree of gloss).

Finally, at block 745, a metallic coating (e.g., chromium plating) istypically applied to the surface of the press plate. In someembodiments, the metallic coating functions to provide a further degreeof gloss to the press plate. In some instances, a protective layer isapplied over portions of the surface of the press plate prior toapplying the metallic coating so that the metallic coating is onlyapplied to areas not covered by such protective layer.

In some embodiments, the steps described with respect to blocks 725 and730 might not be performed. Rather, multiple degrees of gloss may beachieved by repeating the steps described with respect to blocks 735 and740 one or more times.

FIG. 8 depicts a general process flow 800 for creating a textured pressplate in accordance with one or more embodiments of the invention.Initially, at block 805, a mask (or any protective layer) is applied toportions of the surface of the press plate. Next, at block 810, themasked surface of the press plate is processed (e.g., via chemicaletching) to obtain a desired surface structure. As indicated in theprocess flow 800, the steps represented in blocks 805 and 810 may berepeated any number of times to achieve a structured surface of thepress plate that meets a desired design. For example, the desired designmay be that of a wood panel with detailed fine grain structures, a stonepanel, a composite panel, and the like.

Once the desired structure of the press plate has been achieved, theprocess 800 may continue to block 815 and 820, where the surface of thepress plate is polished and cleaned. In some embodiments, polishingand/or cleaning the surface of the press plate may include activatingthe surface of the press plate for better adhesion of a protective layerand/or a metallic coating layer.

In some embodiments, additional processing steps may occur before,between, after, and/or in the place of blocks 815. These additionalprocessing steps include, but are not limited to, additional polishingof the surface, additional cleaning of the surface, matting of thesurface, partial chromium plating of the surface, full chromium platingof the surface, activation of the surface, and the like.

At block 825, a layer of chromium plating is applied to the entiresurface of the press plate, where the chromium plating layer gives thesurface a first degree of gloss. This first full layer of chromiumplating can serve to protect the processed structure of the press platesurface, provide the first layer of gloss, provide a base for additionalgloss-adjusting layers, and the like. In some embodiments, this firstfull chromium plating layer comprises a relatively high level of gloss,while in other embodiments, this first full chromium plating layer isadded in such a manner that the chromium plating is matted as it isapplied to the surface to provide a relatively low level of gloss.

Once the chromium plating layer of block 825 has been applied, theprocess 800 may continue to blocks 830 and 835, where a protective layeris applied over portions of the surface of the press plate, and theportions of the press plate not covered by the protective layer areadjusted to achieve a different level of gloss. This adjustment step ofblock 835 can be completed using any technique described or otherwiseembodied herein. For example, the surface may be polished (e.g.,mechanical polishing or electropolishing), the surface may be matted(e.g., via matte etching, sandblasting, chemical etching, etc.), or ametallic coating (e.g., a partial chromium plating) can be applied tothe surface. The protective layer of block 830 can then be removed,leaving the first level of gloss on the surfaces that had been coveredby the protective layer.

In some embodiments, multiple or additional gloss-adjusting steps may beperformed on the surface of the press plate. Again, thesegloss-adjusting steps may include, but are not limited to, polishing,matting, and metallic coating of the surface. Furthermore, each of thesegloss-adjusting steps may or may not be preceded by the application of aprotective layer (e.g., the same protective layer as in block 830, adifferent protective layer, or a different protective layer covering thesame area as the protective layer in block 830). For example, theprocess 800 may include polishing the surface at block 835, which isfollowed by a set of protective layer and matting steps that covers anoverlapping area of the polishing from block 835.

While these additional gloss-adjusting steps are contemplated, typicallythe process 800 moves from the first gloss-adjusting step in block 835directly to block 840, where a second layer of chromium plating can beapplied to across the entire surface of the press plate. This secondlayer of chromium plating is applied on top of the first chromiumplating (i.e., from block 825), and the gloss adjusting steps (i.e.,from blocks 830 and 835) that were performed on the first layer ofchromium plating. As such, this second layer of chromium platingprotects the entire surface of the press plate (or at least the entireportion of the surface that will be used to stamp out panels) frominadvertent tampering with the press plate structure or gloss levels,and from the introduction of impurities to the press plate surfacesystem that could affect the sensitive qualities of the surface aftercertain gloss adjustment steps have been performed. Additionally, thissecond layer of chromium plating adjusts the level of gloss across theentire surface of the press plate. Note, however that any previous glossadjustments to portions of the surface would continue to provide adifferent level of gloss, as compared to the portions of the surfacethat did not receive a previous gloss adjustment. In any event, theinclusion of this second chromium plating step provides additional andimportant improvements to the visual and functional properties of thepress plate that would not otherwise be obtained by a process that omitsthis step. Indeed, the visual effect from implementing this second fullchromium plating step is different from a visual effect of polishing ormatting the surface of the press plate.

After the second full chromium plating step has been conducted, theprocess 800 may continue to blocks 845 and 850, where a protective layeris applied over portions of the surface of the press plate, and theportions of the press plate not covered by the protective layer areadjusted to achieve a different level of gloss. This adjustment step ofblock 850 can be completed using any technique described or otherwiseembodied herein. For example, the surface may be polished (e.g.,mechanical polishing or electropolishing), the surface may be matted(e.g., via matte etching, sandblasting, chemical etching, etc.), or ametallic coating (e.g., a partial chromium plating) can be applied tothe surface. The protective layer of block 845 can then be removed,leaving the previous level of gloss at the surfaces that had beencovered by the protective layer. Additionally, and as described abovewith respect to block 835, additional gloss-adjusting steps (e.g.,matting, polishing, partial metallic plating) can be performed afterblock 850.

That said, while these additional gloss-adjusting steps arecontemplated, typically the process 800 moves from the second partialgloss-adjusting step in block 850 directly to a final step of block 855,without any additional partial gloss-adjusting steps.

In block 855, a final chromium plating layer is applied to the entiresurface of the press plate. This final chromium plating layer provides afinal protective layer for all structural and gloss-adjustment stepspreviously conducted. The final chromium plating of the entire surfacecreates a strong interface that retains its structured shape whenstamping the press plate into panels. The final chromium plating layeralso preserves the gloss levels of each portion of the press plate. Insome embodiments, the final chromium plating does adjust the gloss levelof the entire surface. This adjustment may be uniform, such that eacharea of varied gloss levels may increase or decrease in the same amount,or in a proportional amount relative to the normal gloss level of theapplied final chromium plating layer.

FIG. 9 illustrates a sample press plate 900 and its structured and/orgloss-adjusted design. As described above, the press plate 900 can bestructured to resemble a known substance (e.g., wood, rock, composite,etc.), or can be structured to resemble an image, or the like. As shownin FIG. 9, the surface can closely resemble the structure of wood,including pores, grain, streaks, knots, and the like. While thestructuring of the press plate can be completed to achieve a verydetailed design, the levels of gloss for each structural component ofthe press plate 900 provides a specific amount of shine that can betailored to resemble the precise gloss levels of minute features ofwood. Therefore, the gloss-adjusting techniques described herein areimportant in providing a press plate 900 capable of stamping out a panelthat compellingly resembles a wood surface.

FIG. 10 depicts a series of cross-sections of a press plate 1000 as itundergoes a process 1100 for structuring the press plate 1000 and forobtaining varied degrees of gloss at certain portions of the press plate1000. This process 1100 illustrates the physical changes to a pressplate 1000 as it undergoes one or more embodiments of the process 800described in FIG. 8.

The process 1100 begins at step 1105, where a base press plate 1005 iscreated, forged, obtained, or otherwise generated. Next, at step 1110, amask 1010 or other protective layer is applied to portions of thesurface of the base press plate 1005. Once the mask 1010 is applied, themasked surface of the based press plate 1005 is processed (e.g., viachemical etching) to obtain a desired surface structure. Step 1115illustrates how the portions of the surface of the base press plate 1005are processed (e.g., eroded, cut out, dissolved, etched, etc.) to formrecessions 1015 in the base press plate 1005. The processing steps canbe repeated with varied masking positions to obtain a specific desiredsurface structure of the base press plate 1005. While FIG. 10illustrates straight, block-like recessions 1015, it is contemplatedthat the structure can form and configuration, such that the surface ofthe base press plate 1005 may include recessions 1015 that are angled,curved, jagged, and the like. As such, the surface of the base pressplate 1005 can be configured to be either exactly conforming to adesired structure for the press plate, or to a structure that is closeto the desired structure, where additional partial metallic plating mayprovide additional structural details later.

Once the base press plate 1005 has achieved its desired structure, thesurface of the base press plate 1005 may be cleaned, polished, and/oractivated. Next, as shown at step 1120, the entire surface of thestructured base press plate 1005 may be coated with a first layer ofchromium plating 1020. While this chromium plating 1020 layer andsubsequent chromium plating layers 1035 and 1050 are referred to only aschromium plating, it is known that any other metallic coating could beapplied and this example is not intended to be limiting to only chromiumplating. This layer of chromium plating 1020 provides a first degree ofgloss across (e.g., formed over) the entire surface of the press plate1000. The chromium plating 1020 also serves to protect the processedstructure of the press plate 1000, provide a solid base for additionalgloss-adjusting layers or processes, and the like.

Once the chromium plating 1020 has been applied, the process 1100 maycontinue to step 1125, where a protective layer 1025 is applied toportions of the surface of the press plate 1000. As used herein, theterm “press plate 1000” refers to the base press plate 1005 and anyother layers, gloss-adjusted surfaces, masks, and the like that make upthe product of the press plate 1000, through any stage of the process1100. The term “surface of the press plate 1000” refers to the topsurface of the press plate 1000, including any protective layers,metallic plating, polished surfaces, matted surfaces, and the like. Theterm “base press plate 1005” refers to the original base press plate1005 and the structured base press plate 1005, on which chromium layersand other gloss adjusting steps are applied.

The protective layer 1025 is configured to protect the surface of thepress plate 1000 that is covered by the protective layer 1025 from anygloss adjusting processing steps that may be performed while theprotective layer 1025 is in place. As such, the protective layer 1025may be positioned in orientations that will allow the surface of thepress plate 1000 to be polished in accordance with desired gloss-levels,based on the desired design.

Step 1130 illustrates an embodiment of the press plate 1000 where thegloss level of the surface of the press plate 1000 has been adjusted bysome gloss adjusting technique while the protective layer 1025 was inplace. Of course, the protective layer 1025 is removed in the embodimentillustrated at step 1130. Portions of the surface of the press plate1000 that were not covered by the protective layer 1025 now include anadjusted gloss level 1030. The gloss adjusting technique may be anygloss adjusting technique described herein. For example, polishing(e.g., mechanical polishing or electropolishing), matting (e.g., viamatte etching, sandblasting, chemical etching, etc.), or metalliccoating (e.g., a partial chromium plating). In some embodiments,additional gloss-adjusting techniques can be applied to the surface ofthe press plate 1000, possibly at different portions of the surface ofthe press plate 1000, to achieve a specific desired gloss level at thisstage in the process 1100.

Next, as illustrated at step 1135, a second layer of chromium plating1035 is applied across (e.g., formed over) the entire surface of thepress plate 1000. As step 1130 shows, this chromium plating 1035 isapplied on top of the first chromium plating 1020, including the glossadjusted surfaces 1030. As such, this second layer of chromium plating1035 protects the entire surface of the press plate 1000 (or at leastthe entire portion of the surface of the press plate 1000 that will beused to stamp out panels) from inadvertent tampering with the pressplate 1000 structure or gloss levels, and from the introduction ofimpurities to the press plate 1000 product that could affect thesensitive qualities of the glossy surface.

Additionally, this second layer of chromium plating 1035 adjusts thelevel of gloss across (e.g., formed over) the entire surface of thepress plate 1000. Note, however, that any previous gloss adjustments toportions of the surface (e.g., the gloss adjusted surface 1030) wouldcontinue to provide a different level of gloss to portions of thesurface that did not receive the previous gloss adjustments.

After the second full chromium plating step has been conducted, theprocess 1100 may continue to step 1140, where a new protective layer1040 is applied over portions of the surface of the press plate 1000.This protective layer 1040 may be the same as, be different from, oroverlap portions of the first protective layer 1025, based on thedesired positions of gloss adjusted surfaces.

Next, the surface of the press plate 1000 is subjected to a glossadjusting step, such that the portions of the press plate 1000 surfacethat are not covered by the protective layer 1040 are subjected to thegloss adjusting step. Step 1145 illustrates an embodiment of the pressplate 1000 after the surface of the press plate 1000 has undergone thegloss adjusting step and the protective layer 1040 has been removed. Asshown in step 1145, a new gloss adjusted portion 1045 of the surface ofthe press plate 1000 is defined by the surface area that was not coveredby the protective layer 1040.

The gloss adjusting technique may be any gloss adjusting techniquedescribed herein. For example, polishing (e.g., mechanical polishing orelectropolishing), matting (e.g., via matte etching, sandblasting,chemical etching, etc.), or metallic coating (e.g., a partial chromiumplating). In some embodiments, additional gloss-adjusting techniques canbe applied to the surface of the press plate 1000, possibly at differentportions of the surface of the press plate 1000, to achieve a specificdesired gloss level at this stage in the process 1100.

Finally, the process 1100 moves to step 1150, where a final chromiumplating 1050 layer is applied to the entire surface of the press plate1000. This final chromium plating 1050 layer provides a final protectivelayer for all structural and gloss-adjustment steps previouslyconducted. The final chromium plating 1050 of the entire surface createsa strong interface for the press plate 1000 that retains its structuredshape when stamping the press plate 1000 into panels. The final chromiumplating 1050 layer also preserves the gloss levels of each portion ofthe press plate. In some embodiments, the final chromium plating 1050does adjust the gloss level of the entire surface of the press plate1000. This adjustment may be uniform, such that each area of variedgloss levels may increase or decrease in the same amount, or in aproportional amount relative to the normal gloss level of the appliedfinal chromium plating 1050 layer.

As used herein, the term “entire surface,” for example, when referringto applying a chromium plating layer to an entire surface of a pressplate, refers at least to the portions of the surface of the press platethat will be interacting with (i.e., pressing or stamping into) panels.However, in some embodiments, the entire surface may refer to the entiresurface of the press plate, including portions of the press plate thatare beyond the surface that will be interacting with panels (e.g.,handles, flanges, extra material, etc.). As such, the term “workingsurface” shall refer to those portions of the surface that are intendedto be used in the pressing or stamping process. Therefore, in someembodiments, the chromium plating steps may comprise applying a chromiumplating layer to the entire working surface of the press plate. Inembodiments described herein, the term “entire surface” may be replacedwith “entire working surface.”

Embodiments of the present invention are described above with referenceto flowcharts and/or block diagrams. It will be understood that steps ofthe processes described herein may be performed in orders different thanthose illustrated in the flowcharts. In other words, the processesrepresented by the blocks of a flowchart may, in some embodiments, be inperformed in an order other that the order illustrated, may be combinedor divided, or may be performed simultaneously.

While certain exemplary embodiments have been described and shown in theaccompanying drawings, it is to be understood that such embodiments aremerely illustrative of, and not restrictive on, the broad invention, andthat this invention not be limited to the specific constructions andarrangements shown and described, since various other changes,combinations, omissions, modifications and substitutions, in addition tothose set forth in the above paragraphs, are possible. Those skilled inthe art will appreciate that various adaptations and modifications ofthe just described embodiments can be configured without departing fromthe scope and spirit of the invention. Therefore, it is to be understoodthat, within the scope of the appended claims, the invention may bepracticed other than as specifically described herein.

1. A textured press plate prepared by a process comprising the steps of:applying a mask to a working surface of a press plate; processing theworking surface of the press plate to obtain a structure in the workingsurface of the press plate; polishing the working surface of the pressplate; cleaning the working surface of the press plate; applying a firstmetallic coating to the entire working surface of the press plate;applying a first protective layer over portions of the working surfaceof the press plate; adjusting a level of gloss for a portion of theworking surface of the press plate not covered by the first protectivelayer; removing the first protective layer; applying a second metalliccoating to the entire working surface of the press plate; applying asecond protective layer over portions of the working surface of thepress plate; adjusting a level of gloss for a portion of the workingsurface of the press plate not covered by the second protective layer;removing the second protective layer; and applying a third metalliccoating to the entire working surface of the press plate.
 2. Thetextured press plate according to claim 1, wherein the first metalliccoating, the second metallic coating, or the third metallic coatingcomprises a chromium plating.
 3. The textured press plate according toclaim 1, wherein adjusting the level of gloss for the portion of theworking surface of the press plate not covered by the first protectivelayer further comprises: polishing the working surface of the pressplate not covered by the first protective layer; matting the workingsurface of the press plate not covered by the first protective layer; orapplying a new metallic coating to the working surface of the pressplate not covered by the first protective layer.
 4. The textured pressplate according to claim 1, wherein adjusting the level of gloss for theportion of the working surface of the press plate not covered by thesecond protective layer further comprises: polishing the working surfaceof the press plate not covered by the second protective layer; mattingthe working surface of the press plate not covered by the secondprotective layer; or applying a new metallic coating to the workingsurface of the press plate not covered by the second protective layer.5. The textured press plate according to claim 1, wherein the processfurther comprises: in response to adjusting the level of gloss for theportion of the working surface of the press plate not covered by thefirst protective layer, applying a new protective layer over portions ofthe working surface of the press plate; and adjusting the level of glossfor the portion of the working surface of the press plate not covered bythe new protective layer.
 6. The textured press plate according to claim1, wherein the process further comprises: after processing the workingsurface of the press plate to obtain the structure in the workingsurface of the press plate, applying a new mask to the working surfaceof a press plate; and processing the working surface of the press plateto obtain an additional structure in the working surface of the pressplate at portions of the working surface of the press plate that are notcovered by the new mask.
 7. A textured press plate, wherein a workingsurface the textured press plate comprises: a base press plate layercomprising a structure therein; a first chromium plating layer formedover the entire base press plate layer, wherein a surface of the firstchromium plating layer comprises varied gloss levels; a second chromiumplating layer formed over the entire first chromium plating layer,wherein a surface of the second chromium plating layer comprises variedgloss levels; and a third chromium plating layer formed over the entiresecond chromium plating layer.